Pallet Circulation System

The Pallet Circulation System is composed of four core sections:

1. Raw Material Handling Area
Responsible for material storage, batching, weighing, conveying, and concrete mixing.

2. Reinforcement Processing Area
Equipped with automated rebar cutting, bending, and welding systems, along with robotic units for precise rebar placement.

3. PC Production Area
Includes pallet circulation systems, pallet cleaning and release agent application units, CAD-controlled plotting systems, shuttering and deshuttering robots, concrete spreaders, vibration and surface finishing equipment, tilting stations, transfer carriages, and vertical pallet racks.

4. Curing & Storage Area
Comprises curing chambers, vertical stacking racks, and systems for automated pallet handling, storage, and internal logistics.

Pallet Circulation System

Each pallet consists of a vibration-resistant welded steel frame with a polished flat surface, serving as the casting platform for precast elements. From pallet cleaning through curing and demoulding, the pallet acts as the carrier throughout all production stages.

The circulation system enables automated, continuous production of various precast elements such as double walls, insulated double walls, solid walls, sandwich walls, façade panels, lightweight concrete walls, lattice girder floors, and solid slabs.

Pallet Cleaning and Release Agent Spraying Devices

The cleaning unit removes concrete residue using a rotating scraper for coarse cleaning, side-mounted brushes for shutter edges, and a rotary brush for final surface cleaning.
The release agent spraying system applies form oil to the entire pallet surface or selectively to designated casting areas, ensuring smooth demoulding and surface finish quality.

Plotter, Shuttering Robot, and Deshuttering Robot

The CAD-controlled plotter marks the full-scale outlines of each precast element directly on the pallet surface, based on the production design.
Shuttering robots place side forms accurately using data from the system and automatically retrieve them from the shuttering storage.
Deshuttering robots identify and remove shutters using a scanning system, improving automation and reducing manual labour.

Concrete Spreader

The concrete spreader distributes freshly mixed concrete into the pallet moulds that have been pre-fitted with shutters. It ensures uniform placement of concrete within the designated moulding zones based on the geometry and strength requirements of each precast element.
Depending on the level of automation required, the spreader can operate manually or as part of a fully automated process.

Compacting and Smoothing Equipment

The compacting system removes air bubbles and ensures proper aggregate distribution through horizontal or combined horizontal and vertical vibration.
The smoothing unit refines the exposed surface of the precast element. It typically features a rough levelling disc and a precision wing trowel mounted on a vertical lift for fine surface finishing.

Pallet Rack and Stacker

After casting, the loaded pallet is transferred to a multi-level vertical curing rack. Automated lifting and stacking systems move the pallet to the assigned level to maximise space utilisation. Once the curing process is complete, the pallet is removed from the rack and transferred to the next stage.

Tilting Equipment and Run-off Carriage

The tilting table lifts and tilts the cured element vertically for safe removal from the pallet, facilitating subsequent handling and transport.
The run-off carriage moves the finished elements to an open-air storage yard or further downstream handling areas.

Curing Chamber

The modular curing chamber is fully enclosed and climate-controlled, supporting efficient and standardised curing of precast elements.

Key features include:
High-efficiency misting and air circulation system using micro-perforated ring pipes for uniform humidity and temperature distribution.
External heating and cooling units to avoid internal corrosion and prolong equipment life. Heating uses a combination of electric and heat pump systems, while cooling incorporates variable-frequency technology.
User-friendly control system with precise temperature and humidity regulation.

Conclusion

The Pallet Circulation System offers a high level of automation, minimising labour while improving consistency, productivity, and production traceability. Its modular design supports flexible scaling and process integration across all stages—from raw material handling to reinforcement preparation, component casting, and curing. It is ideally suited for high-volume, high-quality precast concrete production.